Flexible printed circuit board for catheter, catheter using same, and production method of catheter

ABSTRACT

The present invention provides a flexible printed circuit board  100  having a band-like meander pattern as a whole, which includes multiple linear parts  1  configured in about parallel to each other and a folding margin connected to one end in the longitudinal direction of two adjacent linear parts of the multiple linear parts, and which can turn into a single linear product having a total length of not less than 300 mm when the folding margin  2  is double-folded at the about center thereof, and, at the folding margin  2,  either of the two linear parts  1  connected to the folding margin  2  is folded back in the direction opposite by 180 degrees. As a result, a flexible printed circuit board for a catheter, which is sufficiently elongate for use as a signal line of a catheter, can be produced using a general-purpose production apparatus, which improves the degree of freedom of movement in a tube.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a flexible printed circuit board for a catheter, a catheter using the circuit board, and a production method of the catheter. More particularly, the flexible printed circuit board for a catheter is long but easy to manufacture, and improves the degree of freedom of the deformation and movement in a tube.

BACKGROUND OF THE INVENTION

Conventionally, various tests and treatments are performed based on the electrical signals transmitted by electronic components, such as a heat element, a pressure sensor, a temperature measurement thermistor and the like, set in the anterior end or an intermediate part of a tube of a catheter inserted into the body of patients. Such an electronic component-loaded catheter is described, for example, in JP-A-11-56794 and JP-A-2001-170013.

The aforementioned “anterior end of a tube” means an end of the head of a catheter (tube) in the length direction, which is to be inserted into the body of patients, and the “anterior end of a tube” in the following description in the present specification means an end of the head of a catheter (tube) in the length direction when inserted into the body of patients, and the “posterior end of a tube” means the other end of the tube, which is the opposite side from the head, in the length direction.

In the above-mentioned catheter comprising an electronic component in a tube, an electrical signal sent by an electronic component in the anterior end or an intermediate part of a tube inserted in the body of patients is processed by a measuring apparatus etc. connected to the posterior end of the tube outside the body of patients. When the operation of the aforementioned electronic component is to be controlled, it is remotely controlled by a control device connected to the posterior end of a tube outside the body of patients. Therefore, a signal line to transmit an electrical signal between the electronic component and a measuring apparatus, a control device and the like needs to be installed in the tube of an electronic component-loaded catheter. As such signal line, signal cables such as flat cable etc. have been conventionally used, as in the catheters described in the aforementioned JP-A-11-56794 and JP-A-2001-170013. Recently, however, for higher functions of electronic components to be set in a tube, this kind of catheter is required to contain an increased number of signal lines. When the number of signal cables is increased to contain many signal lines, the tube containing the signal cables needs to be made thicker. As a result, problems of lower operability of catheter in the body of patients, increased pain felt by patients during operation of catheter and possible damage in the body of patients occur. Since the mounting site of an electronic component is limited to a specific area at the tip of a signal cable, the number of electronic components to be mounted is limited. In addition, since the position of the electronic components to be mounted is limited to the tip of a signal cable, the place where the electronic components operate as well as their functions are problematically limited.

Therefore, the present inventors have considered using a flexible printed circuit board as a signal line to be installed in a tube. To be specific, since a flexible printed circuit board can form an ultrafine high density wiring, when it is used as a signal line to be installed in a tube, the number of signal lines can be increased without greatly increasing the thickness of the tube. Since a terminal mounting an electronic component can be formed at a given position in a flexible printed circuit board, moreover, the positions and number of the electronic components to be installed can be easily designed.

When a flexible printed circuit board is inserted in a tube for use as a signal line, however, since the flexible printed circuit board needs to be formed in a long, linear pattern, the production cost of a product showing highly uniform properties becomes high. To be precise, in most cases, a photolithography step is included in the production of a flexible printed circuit board, which uses a general-purpose exposing apparatus having an exposure area of a generally about 250 mm×250 mm square. When one linear flexible printed circuit board having a total length of not less than 300 mm is to be produced, it needs to be exposed to light multiple times in multiple steps, or an exposure mask having a considerably extended length needs to be prepared, or an exposure surface needs to have a considerably large linear length, which causes a high cost. Moreover, exposure in multiple times in multiple steps may result in occurrence of disconnection between the exposed areas.

In addition, while a flexible printed circuit board is advantageous for decreasing the diameter of a catheter as compared to wire cables, the degree of freedom of movement in a tube is generally smaller than wire cables, and the operability (deformability) of a catheter using a flexible printed circuit board as a signal line is not entirely satisfactory.

In view of the above-mentioned situation, the problem to be solved by the present invention is provision of a flexible printed circuit board for a catheter, which is sufficiently elongate for use as a signal line of a catheter, can be produced using a general-purpose production apparatus, and can improve the degree of freedom of movement in a tube, a catheter comprising the flexible printed circuit board and a production method thereof.

SUMMARY OF THE INVENTION

The present invention solves the above-mentioned problem by the following constitutions.

(1) A flexible printed circuit board for a catheter,.which is formed in a single non-linear band-like pattern having a folding margin at a predetermined position, wherein said flexible printed circuit board can turn into a single linear product when folded at said folding margin.

(2) The flexible printed circuit board of the above-mentioned (1), wherein said single linear product has a total length of not less than 300 mm.

(3) The flexible printed circuit board of the above-mentioned (1),

which has a band-like meander pattern as a whole,

which comprises multiple linear parts configured in about parallel to each other and a folding margin connected to one end in the longitudinal direction of two adjacent linear parts of said multiple linear parts, and

which can turn into a single linear product when the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either of the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees.

(4) The flexible printed circuit board of the above-mentioned (3), wherein the single linear product has a total length of not less than 300 mm.

(5) The flexible printed circuit board of the above-mentioned (1), wherein the size of the band-like pattern as a whole before folding is within a 250 mm×250 mm square area.

(6) The flexible printed circuit board of the above-mentioned (1), which further comprises a metal support plate disposed in an area other than the folding line.

(7) The flexible printed circuit board of the above-mentioned (1), wherein two opposite substrate surfaces after folding at a folding margin are adhered via an adhesive layer.

(8) A catheter comprising the flexible printed circuit board of the above-mentioned (1) in the form of a single linear product inserted in a tube.

(9) A production method of a catheter, which comprises

step 1: folding the flexible printed circuit board of the above-mentioned (1) at a folding margin to give a single linear product, and

step 2: inserting the resulting flexible printed circuit board in a tube.

(10) The production method of the above-mentioned (9), wherein the step (1) comprises adhering, via an adhesive layer, two opposite substrate surfaces after folding at a folding margin.

(11) A production method of a catheter, which comprises

step 1: folding a flexible printed circuit board of the following (I) at a folding margin to give a single linear product, and

step 2: inserting the resulting flexible printed circuit board in a tube, wherein,

in step 1, the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either of the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees, so as to convert the circuit board into a single linear product;

(I) a flexible printed circuit board for a catheter,

which is formed in a single non-linear band-like pattern having a folding margin at a predetermined position, wherein said flexible printed circuit board can turn into a single linear product when folded at said folding margin,

which has a band-like meander pattern as a whole,

which comprises multiple linear parts configured in about parallel to each other and a folding margin connected to one end in the longitudinal direction of two adjacent linear parts of said multiple linear parts, and

which can turn into a single linear product when the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either of the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified plan view of the flexible printed circuit board for a catheter of one embodiment of the present invention.

FIG. 2 is an enlarged view of the area A encircled with a dotted line in FIG. 1.

FIG. 3 shows simplified views of how the flexible printed circuit board for a catheter of the present invention is sequentially folded to form a linear product.

FIG. 4 is a simplified view of a linear product obtained by folding the flexible printed circuit board for a catheter as shown in FIG. 1 at the folding margin into one linear product.

FIG. 5 shows deformation examples of the folding margin of the flexible printed circuit board for a catheter of the present invention.

FIG. 6 is a sectional view of the flexible printed circuit board for a catheter shown in FIG. 1.

FIG. 7 is a plan view of one embodiment of the arrangement of terminals in the flexible printed circuit board for a catheter of the present invention.

FIG. 8 is a plan view of another embodiment of the arrangement of terminals in the flexible printed circuit board for a catheter of the present invention.

FIG. 9 is a plan view of one embodiment of exposure of a terminal in the flexible printed circuit board for a catheter of the present invention.

FIG. 10 shows simplified views of arrangements of metal support plates in the flexible printed circuit board for a catheter of the present invention.

FIG. 11 includes simplified side views showing folding part stabilized structures in the flexible printed circuit board for a catheter of the present invention.

FIG. 12 is a simplified sectional view showing a connection part between an electronic component and a flexible printed circuit board and the vicinity thereof in the tube of a catheter in the present invention.

FIG. 13 is a simplified plan view of the flexible printed circuit board for a catheter prepared in Example 1.

FIG. 14 shows a deformation example of the folding margin of the flexible printed circuit board for a catheter of the present invention.

In the Figures, each reference number designates the following. 1: linear part, 2: folding margin, 10: base insulating layer, 11: wiring pattern, 12:cover insulating layer, 100: flexible printed circuit board (FPC).

DETAILED DESCRIPTION OF THE INVENTION

While the flexible printed circuit board for a catheter of the present invention is originally a non-linear product, it can turn into a single linear product by folding at folding margin(s).

Thus, it is possible to produce a non-linear circuit board product having a size of the whole band-like pattern before folding within, for example, a 250 mm×250 mm square area. Then, the circuit board can turn into a linear product having a total length of not less than 300 mm by folding at folding margin(s).

In the photolithography step during production, therefore, it is not necessary to conduct the exposure multiple times in plural steps or use a light exposure mask having a considerably extended linear part. Instead, the light exposure can be applied all at once using a general-purpose exposing apparatus, by which the production cost can be suppressed. -In addition, a flexible printed circuit board for a catheter having highly uniform properties can be realized.

In a flexible printed circuit board formed into a single linear product by folding at folding margin(s), the folded part absorbs the stress applied to the linear parts before and after the folded part, and therefore, the degree of freedom of movement in a tube becomes high. Therefore, when the flexible printed circuit board of the present invention is used as a signal wiring, a catheter having a small diameter and superior operability (deformability) can be realized.

The present invention is explained in more detail in the following by referring to the Figures.

FIG. 1 is a plan view of the flexible printed circuit board for a catheter of one embodiment of the present invention and FIG. 2 is an enlarged view of the main part (area A encircled with a dotted line) in FIG. 1.

As shown in said embodiment of the flexible printed circuit board (hereinafter to be also abbreviated as “FPC”) 100, the flexible printed circuit board for a catheter of the present invention has been formed in a non-linear, elongate band-like pattern having a total length of generally not less than 300 mm. In FIG. 2, 11 is a wiring pattern and 12 is a cover insulating layer. The wiring pattern 11 is formed on a base insulating layer not shown, and the cover insulating layer 12 is formed to cover the wiring pattern 11.

In said embodiment, the flexible printed circuit board 100 comprises multiple linear parts 1 configured in about parallel to each other and folding margins 2 connected to one end of the end portions in the longitudinal direction of the each set of two adjacent linear parts 1 of the multiple linear parts, and has a band-like meander pattern as a whole. The flexible printed circuit board 100 turns into a single linear product upon predetermined folding at the individual folding margins 2.

To be specific, the folding margin 2 is, as shown in FIG. 3(a), double-folded such that a folding line L2 parallel to the axis L1 of the linear part 1 is formed in the about center thereof as shown in FIG. 3(b), and, as shown in FIG. 3(c), either of the two linear parts 1. (1A, 1B) connected to the folding margin 2 is folded back in the direction opposite by 180 degrees. This step is performed at individual folding margins 2 to give a single linear product having a total length of not less than 300 mm (FIG. 4).

As mentioned above, the inventive FPC for a catheter is, as shown in FPC 100 of the above-mentioned embodiment, has a single non-linear band-like pattern before folding at folding margin(s) 2, and can change into a single linear product having a total length of not less than 300 mm by folding at folding margins 2 formed at predetermined positions. In addition to this constitution, the whole band-like pattern before folding is configured to a size within a square area of 250 mm×250 mm. As a result, during a photolithography step for production, it is not necessary to conduct the exposure multiple times in plural steps or use a light exposure mask having a considerably extended linear part. Instead, the light exposure can be applied all at once using a general-purpose exposing apparatus. Therefore, a product having highly uniform properties can be obtained free of high production costs.

When FPC is a single linear product having a total length of not less than 300 mm by predetermined folding at each folding margin 2, the folded part in the folding margin 2 absorbs the stress applied to the linear parts before and after the folded part, and therefore, the degree of freedom of movement in a tube becomes high. Therefore, when the FPC of the present invention is used as a signal wiring to be connected to an electronic component, a catheter having superior operability can be realized.

The “non-linear band-like pattern” of the inventive FPC for a catheter before folding at folding margin(s) means a pattern comprising combinations of multiple linear parts and bending parts to be the folding margins, so as to avoid an FPC elongate in one direction alone.

This pattern may be other than the meander pattern such as FPC 100 in the above-mentioned embodiment, which is exemplified by an eddy or volute pattern and the like. Since the manner of folding at folding margins to produce a single linear product can be simplified, the meander pattern of FPC 100 in the above-mentioned embodiment is preferable.

Furthermore, the “single linear product after folding at folding margin(s)” means that, in a plan view, the FPC as a whole generally appears to be a single linear product after folding at folding margin(s), and a structure where the axis of the multiple linear parts are aligned in one straight line with high precision is not meant in this context.

When Inventive FPC for a catheter is to be formed into an FPC having a band-like meander pattern as a whole and comprising, as in FPC 100 of the above-mentioned embodiment, multiple linear parts 1 configured in about parallel to each other and a folding margin 2 connected to one end in the longitudinal direction of each set of two adjacent linear parts 1 of the multiple linear parts, the total number of linear parts 1 may be appropriately selected from the range of 2-10 depending on the size (length) and structure of the catheter to be produced, while the FPC of FIG. 1 comprises four linear parts 1.

The length D1 of the linear part 1 (width in the axis direction) is generally selected from the range of 100-400 mm, and the width D2 (width in the direction perpendicular to the axis) is selected from the range of 0.1-3 mm.

The total number of the folding margins 2 is generally selected from the range of 1-9 since the total number of the linear parts 1 is 2-10, and the width D3 in the direction perpendicular to the axis of the folding margin 2 is generally selected from the range of 0.3-10 mm.

The clearance D4 between the adjacent two linear parts 1 is generally within the range of 0.02-5 mm.

In the Inventive FPC for a catheter, the “linear” of the linear parts 1 means that the axis is linear, and the outer line of the linear part 1 may not be linear. In addition, the shape of the folding margin 2 is not particularly limited. For example, the rectangle shape (square shape) as shown in FIG. 2, a semicircle shape and the mixture as in FIG. 5(a), a trapezoid shape as in FIG. 5(b) and the like can be mentioned.

When the folding margin 2 is of such semicircle type or a trapozoid type, the area of the folded part resulting from the folding becomes smaller than that of a square type. In the embodiment of such a folding margin, the possibility of the folding margin 2 extending from the outer shape of a single linear FPC is preferably small, even if the linear parts 1 (axis thereof) before and after the folding margin fail to have a preferable shape where they are aligned in one straight line.

While the total length of the FPC of the present invention when it is a linear product is appropriately determined according to the size (length) and structure of the catheter to be produced, it is generally within the range of not less than 300 mm and not more than 2500 mm.

FIG. 6 is a sectional view of FPC 100 of the aforementioned one embodiment along the plane perpendicular to the axis of the wiring pattern. As shown in FIG. 6, the FPC of the present invention has a laminate structure wherein a base insulating layer 10, a wiring pattern 11 and a cover insulating layer 12 are laminated in this order and is basically the same as that of the conventional FPC. For the material of the base insulating layer 10, wiring pattern 11 and cover insulating layer 12, known materials conventionally used for FPC can be employed.

As the material of the base insulating layer 10, for example, polyimide resin, polyester resin, epoxy resin, urethane resin, polystyrene resin, polyethylene resin, polyamide resin, acrylonitrile-butadiene-styrene (ABS) copolymer resin, polycarbonate resin, silicone resin, fluorine resin and the like can be mentioned. Of these, polyimide resin is preferable from the aspects of heat resistance, size stability, chemical resistance and the like. The thickness of the base insulating layer 10 is preferably about 5-100 μm, more preferably about 8-30 μm, from the aspects of flexibility and electrical insulation.

As the material of the wiring pattern 11, for example, stainless steel, copper, copper alloy, aluminum, copper-beryllium, phosphor bronze, 42 alloy and the like can be mentioned, with preference given to copper and copper alloy, from the aspects of conductivity and rigidity.

The thickness of the wiring pattern 11 is preferably 3-50 μm, more preferably 5-20 μm. When the thickness of the wiring pattern 11 is less than 3 μm, it is unpreferably susceptible to damage due to a mechanical stress such as bending and the like, local pressure, wear and the like, and when it is greater than 50 μm, wiring at a fine pitch is difficult to achieve, and deformation does not occur easily.

The width of the wiring pattern 11 is preferably 5-100 μm, and the space between the adjacent wirings in multiple wiring patterns 11 is preferably as narrow as possible within the range free of inconveniences such as occurrence of unnecessary noise to electrical signals, short circuit due to metal ion migration and the-like, and it is generally selected from the range of 5-100 μm.

Generally, a part (normally an end) of the wiring pattern 11 is not covered with a cover insulating layer 12, and used as a terminal part for an electric connection with other conductor members such as metal wire and the like. Where necessary, the terminal part may be coated with a highly conductive metal such as nickel, gold, solder, tin and the like.

FIGS. 7 and 8 are plan views of the vicinity of the end portion of the multiple wiring patterns of the FPC of the present invention. In the FPC of the present invention, the end portions 11A of the multiple wiring patterns 11 may, as in the embodiment shown in FIG. 7, align in a single straight line, or as in the embodiment shown in FIG. 8, the end portion on the tip side and the end portion on the posterior end side may be alternately arranged to form a pattern. The end portion 11A may be made to have a pattern formed by end portions having different positions alternately arranged as mentioned above, whereby the area of the terminal part (the surface of the end portion) 20 of each wiring pattern can be preferably enlarged and easily connected to a metal wire and the like.

In the embodiments shown in FIG. 7 and FIG. 8, the terminal part (the surface of the end portion) 20 of the wiring pattern is entirely exposed to the outside. As show in FIG. 9, a part of the wiring pattern may be formed to appear from the opening of the cover insulating layer 12.

The thickness of the cover insulating layer 12 is preferably 2-50 μm. When it is less than 2 μm, dispersion in the thickness and partial insulation failure due to bending and wear tend to occur, and when it exceeds 50 μm, flexibility tends to be degraded.

FIGS. 10(a)-(c) are plan views enlarging the main part of the base insulating layer of another embodiment of the FPC of the present invention, which is on the opposite surface from the surface where the wiring pattern is formed. As shown in these Figures, the FPC of the present invention may have a structure where a metal support plate 13 is laminated on the surface of the base insulating layer 10, which is opposite from the surface where the wiring pattern 11 is formed.

When FPC has such metal support plate 13, insertion of the FPC into a tube is facilitated, since the metal support plate 13 increases the rigidity of the FPC as a whole. Moreover, unnecessary bending of the catheter and the like do not occur easily, and the catheter can be easily advanced in a desired direction in the body. As a result, the operability of insertion of the catheter into the body is improved.

In the embodiment of FIG. 10(a), a metal support plate 13 is not laminated on the boundary between the folding margin 2 and the linear part 1, and a folding margin 2. The metal support plate 13 is laminated only on the linear part 1.

This embodiment is preferable for insertability into a tube, since the metal support plate 13 is not layered when the folding margin 2 is double-folded and the thickness of the folding part does not increase. In addition, it is superior in the flexibility and can be folded easily.

In the embodiment shown in FIG. 10(b), a metal support plate 13 is not laminated on the boundary between [one (1A) of the two linear parts 1 (1A, 1B) to be folded back in the direction opposite by 180 degrees during the folding step] and the folding margin 2, and the folding margin 2 (about half area of the folding margin) connected to the boundary. In other words, in the embodiment shown in this embodiment, the metal support plate 13 is laminated on two linear parts 1A, 1B, and the metal support plate 13 laminated on the other (1B) of the two linear parts 1 (1A, 1B) not to be folded back in the direction opposite by 180 degrees during the folding step is extended beyond the boundary between the linear part 1B and the folding margin 2 to cover an about half area of the folding margin 2.

In this embodiment, FPC is converted to a single linear product by folding back the linear part 1A (linear part connected to the half area of the folding margin 2, which is free of the metal support plate) in the direction opposite by 180 degrees. In this case, when FPC is converted to a single linear product, since the metal support plate 13 is present on the folding part, the rigidity of the whole linear product can be enhanced uniformly. Therefore, the insertion of the product into a tube is further facilitated, as compared to the FPC in the embodiment of the above-mentioned FIG. 10(a).

In the embodiment of FIG. 10(c), a metal support plate 13 is not laminated on the boundary between a folding margin 2 and two linear parts 1A, 1B connected thereto, and an about half area of the folding margin 2 connected to the boundary with one of the two linear parts 1A, 1B. In other words., in the embodiment of this Figure, the metal support plate 13 is laminated on two linear parts 1A, 1B, and the remaining half of the folding margin 2.

In the FPC of this embodiment, since a metal support plate 13 is not laminated on the boundary between a folding margin 2 and two linear parts 1A, 1B connected thereto, any one of the two linear parts 1A, 1B connected to the folding margin 2 may be folded back in the direction opposite by 180 degrees. Therefore, the folding step for forming a single linear product can be performed rapidly, as compared to the FPC in the embodiment of the above-mentioned FIG. 10(b).

While a metal support plate is absent on the boundary between a folding margin 2 and two linear parts 1A, 1B connected thereto, since the metal support plate 13 is present on a folding margin 2, when FPC is converted to a single linear product, the generally rigidity of the whole linear product can be enhanced, which in turn further facilitates the insertion of the product into a tube, as compared to the FPC in the embodiment of the above-mentioned FIG. 10(a).

To facilitate double-folding of the folding margin 2 and to reduce the stress applied to FPC during folding, as shown in FIG. 14, a through hole H1 may be formed in the part overlapping with the folding line L2 of the folding margin 2. The through hole H1 needs to be formed in the part free of a wiring pattern.

The dotted lines in FIGS. 10(a)-(c) are folding (back) lines formed during folding of FPC. A folding line parallel to the axis of the linear part is formed in the boundary between the folding margin 2 and two linear parts 1A, 1B connected thereto and about center of the folding margin 2. In the wiring circuit board of the present invention, the metal support plate 13 is preferably installed avoiding the part to be the folding line of FPC. As a result, folding of FPC can be completely smoothly.

When FPC is a laminate having a metal support plate 13, the width (width in the direction perpendicular to the axis of FPC) of the metal support plate 13 is preferably smaller than the width (width in the direction perpendicular to the axis of FPC) of the base insulating layer 10 and a metal support plate is absent on both ends in the short (width) direction of FPC (direction perpendicular to the axis of FPC).

By this constitution, even when a corner in the short direction of FPC hits the inner wall of a tube during insertion of FPC in the tube, the inner wall of the tube is not injured and FPC can be inserted smoothly. The difference between the width of the metal support plate and the width of the base insulating layer is preferably about 0.02-0.5 mm.

In the present invention, as a material of the metal support plate 13, a single metal element such as stainless steel, steel, nickel, chrome, iron, tin, lead, aluminum and the like and an alloy of two or more from these metals and the like can be mentioned. Of these, stainless steel is preferable in view of its high elastic modulus.

The elastic modulus of the metal support plate 13 is preferably not less than 50 GPa, more preferably not less than 100 GPa, in consideration of insertability of a flexible printed circuit board into a tube and operability of catheter. However, when the elastic modulus is too high, the metal support plate is difficult to bend after insertion into a tube or lacks flexibility. Thus, the elastic modulus is preferably not more than 400 GPa, more preferably not more than 300 GPa.

As used herein, the “elastic modulus” means tensile elasticity as measured under the test conditions of test piece width 20 mm, distance between chucks 100 mm, tension rate 50 mm/min.

In addition, the thickness of the metal support plate 13 is generally preferably about 10-200 μm, more preferably 20-50 μm. When the thickness of the metal support plate 13 is less than 10 μm, a FPC easily develops curls and swelling, which in turn may render insertion of the FPC into a tube difficult. On the other hand, when it is thicker than 200 μm, flexibility of a FPC is degraded, which in turn may render insertion of the FPC into a tube difficult.

In the present invention, the total thickness of FPC before folding (including both FPC having a metal support plate 13 and FPC free of a metal support plate 13) is preferably 30-300 μm, more preferably 40-150 μm. When the total thickness is smaller than 30 μm, the mechanical strength becomes insufficient and insertion of a tube becomes difficult or wire breakage easily occurs. When the total thickness is greater than 300 μm, the flexibility of catheter is degraded, and operability during insertion of the catheter into the body is degraded.

Inventive FPC for a catheter is folded at a folding margin set at a predetermined position to form a single linear product (generally a linear product having a total length of not less than 300 mm), and then the single linear FPC is inserted in a tube which is an outer packaging of a catheter.

The folding part (overlap of substrate) formed by folding at folding margin(s) may become unstable because the rigidity of FPC tries to restore the shape before folding. To stabilize the shape of the folding part, therefore, two opposite substrate surfaces after folding may be adhered via an adhesive.

FIGS. 11(a), (b) show specific examples of such reinforcing (stabilization) structure. FIG. 11(a) shows a structure wherein a folding margin 2 is double-folded at an about center thereof and the facing surfaces are adhered via an adhesive layer 3. FIG. 11(b) is a structure wherein a folding margin 2 is double-folded at an about center thereof, the facing surfaces are adhered via an adhesive layer 3, and the back of a surface opposite to one of the adhered facing surfaces of the folding margin 2 is adhered to a part of the linear part 1 folded back in the direction opposite by 180 degrees, which is superimposed thereon, with an adhesive (adhesive layer 3).

As an adhesive to be used for the stabilization of the folding part, silicone adhesives, acrylic adhesives, epoxy adhesives and the like can be mentioned.

The thickness of the adhesive layer 3 is preferably 5-50 μm, more preferably 10-30 μm. When the thickness is less than 5 μm, sufficiently high adhesion cannot be achieved easily and when it exceeds 50 μm, the folded part (folding part) may thicken, or the step between the folded part (folded part) and other part (non-folded part) becomes bigger, which unpreferably results in inhibited insertion in a tube and restricted bendability after insertion into the tube.

The production method of the flexible printed circuit board of the present invention is not particularly limited, and the board can be produced by an appropriate combination of known membrane (layer) forming techniques, membrane (layer) patterning techniques, wiring formation techniques and photolithography techniques for printing etc. and the like, conventionally employed for the manufacture of flexible printed circuit boards. For example, it may be combined with a subtractive method, a semi-additive method and the like.

When a base insulating layer 10 and a cover insulating layer 12 are formed in a given pattern, for example, a method using a photosensitive resin (e.g., photosensitive polyimide etc.) (namely, a photosensitive resin (precursor) layer is subjected to exposure, development, heat curing treatment and the like to form an insulating resin layer in a given pattern), a method comprising subjecting an insulating resin layer to etching by laser or with plasma to form a given pattern and the like can be mentioned. In view of workability, positioning accuracy and the like, a method using a photosensitive resin is preferable.

The wiring pattern 11 can be formed, for example, by forming a mask pattern by photolithography techniques, and forming a deposit film of a metal for wiring by metal deposit film forming techniques such as sputtering, plating and the like.

When a flexible printed circuit board having a metal support plate 13 is to be prepared, a flexible printed circuit board having a base insulating layer 10, a wiring pattern 11 and a cover insulating layer 12 laminated in this order is prepared, and the metal support plate 13 may be adhered to the base insulating layer 10 with an adhesive or a base insulating layer 10, a wiring pattern 11 and a cover insulating layer 12 may be laminated in this order on the metal support plate 13.

When a flexible printed circuit board having a metal support plate 13, which is free of a metal support on both ends in the short direction of the plate substrate is to be prepared, a laminate structure having a metal support plate 13 is prepared and the metal support plate 13 is subjected to partial etching.

The catheter in the present invention can be obtained by folding the FPC of the present invention explained above, forming a single linear product by folding at folding margin(s), and inserting the product into a tube.

In other words, the catheter is produced by folding FPC at a folding margin to give a single linear product (step 1), and FPC, which is a single linear product via step 1, is inserted in a tube (step 2).

When the stabilized structure of a single linear FPC having the aforementioned adhesive on the folding parts is to be introduced, the FPC is folded at folding margins to form a stabilized structure and then inserted in a tube.

As explained in the section of BACKGROUND OF THE INVENTION, in general, in a catheter comprising an electronic component in a tube, after insertion of the catheter in the body of patients, electrical signals generated by an electronic component installed in the anterior end or intermediate part of the tube are processed by a measuring apparatus etc. connected to the posterior end of the tube outside the body of the patients, and the electronic component is controlled by remote with a control device connected to the posterior end of the tube outside the body of the patients.

Therefore, in a catheter using the FPC of the present invention, the FPC to be inserted into the tube has a length of at least from the vicinity of the electronic component in the tube to the posterior end of the tube and, after insertion into the tube, an end portion (terminal part) of the wiring pattern exposed at the end portion on the posterior end side of the tube in the longitudinal direction (axis direction) is electrically connected to an outside measuring apparatus, control device and the like.

The end portion of FPC to be connected to an outside measuring apparatus, control device and the like on the posterior end side of the tube may have a width smaller or larger than the inner diameter of a tube, and it may be contained in the tube or extending from the posterior opening of the tube.

As the material of the tube (outer packaging) of the catheter of the present invention, insulating resin materials such as fluororesins (e.g., polytetrafluoroethylene etc.), silicone resin, high density polyethylene resin, polyurethane resin, polyester resin, polyvinyl chloride and the like are used. In consideration of the flexibility, heat resistance, chemical resistance, biocompatibility, processability into tube and the like, fluororesin is preferable.

While the shape of the section (transverse section) perpendicular to the axis of the tube is not particularly limited, a shape free of corners such as circle, ellipse and the like are preferable (generally circle). Taking a circle as an example, the inner diameter thereof is preferably about 0.2-3.5 mm, and the outer diameter thereof is preferably about 0.3-4 mm. The inner diameter and the outer diameter are preferably determined to make the thickness of the tube 0.05-1.0 mm.

When a tube having a sectional shape other than a circle is used, it is preferable that the tube have a section whose maximum diameter of the inner circumference and maximum diameter of the outer circumference are within the preferable numerical ranges of the inner diameter and outer diameter of the above-mentioned circular section.

In the catheter of the present invention, the length (length in the axis direction) of the tube is generally selected from the range of 30-2500 mm.

As an electronic component to be mounted in the tube in the catheter of the present invention, any electronic component conventionally used for electronic component-loaded catheters can be used. Specifically, heat element, pressure sensor, thermistor for temperature measurement, ultrasonic oscillator, piezoelectric element and the like can be mentioned.

When a catheter mounting a pressure sensor is produced, the pressure sensor (electronic component) is disposed such that sensitive surface thereof is exposed from a through hole formed on a side wall of a tube.

In the catheter of the present invention, the connection. (electric connection) between the electronic component 50 and the FPC 100 is formed in a tube 101, for example, by a method comprising, as shown in FIG. 12, metal welding of a terminal part 20 of a wiring pattern 11 of a FPC 100 and a terminal (not shown) of an electronic component 50, as in respective bonding of one end and the other end of a metal wire 7, a method comprising covering both a terminal part 20 formed in a wiring pattern and a terminal of the electronic component 50 with a conductive adhesive layer and the like.

As shown in FIG. 11, the connection between the terminal part 20 of a wiring pattern 11 and a terminal of the electronic component 50 is preferably protected by sealing with a resin 8. As the resin 8 for sealing, for example, epoxy resin, fluorine resin, silicone resin and the like can be mentioned.

For fixing an electronic component in a tube 101, as shown in FIG. 12, the electronic component 50 is preferably mounted (fixed) on an area 10A free of wiring patterns which is adjacent to the terminal part 20 formed in a wiring pattern 11 on a base insulating layer 10 of a FPC. In this way, the wiring pattern 11 and the electronic component 50 both follow movements of a FPC 100, thereby minimizing the load on the connection part between them, and the connection reliability between the terminal of electronic component 50 and terminal part 20 of a wiring pattern 11 is improved.

For mounting (fixing) an electronic component 50 on a base insulating layer 10, for example, as shown in FIG. 12, a resin 8 is used for sealing the connection between a terminal part 20 formed on a wiring pattern 11 and the terminal of the electronic component 50, wherein the resin 8 is applied to an about entire side surface of the electronic component 50, bridging the surface of the base insulating layer 10 and the periphery of the electronic component 50. By this constitution, mounting (fixing) of an electronic component 50 and connection of a terminal of the electronic component 50 to a wiring pattern 11 can be simultaneously performed efficiently. The electronic component 50 may be fixed with an adhesive in an area 10A near the terminal part 20 formed in the wiring pattern 11 on a base insulating layer 10.

As in the catheter 100 of one embodiment shown in FIG. 12, when a catheter having a part of an electronic component 50 exposed from a through hole H formed on the side wall of a tube 101 is produced, it is preferable to apply a sealing resin 9 to cover the periphery of tube walls around the through hole H and an upper surface of the electronic component 50, so as to certainly block the inside of the tube from the outside thereof.

As the resin 9 for sealing, for example, epoxy resin, fluororesin, silicone resin and the like are used. When the sensitive surface of the electronic component does not need to be exposed to the outside a tube, as in a temperature sensor, tube walls may not have a through hole and the electronic component may be enclosed in the tube. In this case, a resin for sealing is not necessary.

EXAMPLES

The present invention is explained in more detail in the following by referring to Examples, which are not to be construed as limitative.

Example 1

In this example, the FPC 200 shown in FIG. 13, which comprises eight wiring patterns formed on a stainless substrate by a semi-additive method was produced.

This FPC 200 has three linear parts 1 and folding margins 2 having a rectangle pattern to connect the linear parts, and has a band-like meander pattern as a whole. An electronic component mounting part 52 is partitioned in the end portion on one side in the axis direction, eight wiring patterns 11 are disposed with each end set close to the electronic component mounting part 52, and terminals 20 for connection with an electronic component are formed on the end. The area containing the electronic component mounting part 52 and terminals 20 of respective wiring patterns 11 is exposed without being covered with a cover insulating layer 12. In the end portion on the other side in the axis direction is partitioned a substrate part 51B having an about square plan shape for connection with an external device. The substrate part 51B contains eight terminals 53 for connection with an external device, which are exposed from the openings formed in the cover insulating layer. The substrate part 51B for connection protrudes outside from the posterior end of a tube when FPC 200 is inserted into the tube. The size of each part is as shown below.

length (D1) of linear part 1: 210 mm

width (D2) of linear part 1: 1 mm

clearance (D4) between adjacent linear parts: 50 μm

width (D3) of folding margin (rectangle pattern part) 2: 2 mm

plane size of substrate part 51B for connection with external device: 8 mm×8 mm

length (D5) of drawing part 54 from ten end of linear part 1 to substrate part 51B for connection: 0.5 mm

distance (D6) from the end edge of FPC on the side where electronic component mounting part 52 is partitioned to the end edge of cover insulating layer 12: 2 mm

length (D7) of exposure of wiring pattern 11 from end edge of cover insulating layer 12: 500 μm

plane size of terminal 20: 80 μm×160 μm

plane size of terminal 53: 1.5 mm×2 mm

An FPC 200 having the above-mentioned structure and size was prepared by the following steps.

First of all, a photosensitive polyimide precursor was applied to a stainless substrate (SUS304)(length: total length. 250 mm, width: 250 mm, thickness: 20 μm, elastic modulus: 205 GPa) as a metal support plate, which was then subjected to light exposure, development and heating to give a 10 μm thick base insulating layer made of polyimide, which has a predetermined shape.

Then, by continuous sputtering, a metal thin film (chrome thin film (thickness: 100 nm)/copper thin film (thickness: 100 nm)) was deposited on the surface of a base insulating layer and a metal support plate. A plating mask having an inverse pattern to-the wiring pattern to be formed was prepared by photoresist (i.e., pattern having the same opening areas as the wiring pattern to be formed).

Then, a copper layer (thickness: 10 μm) was grown on a part free of a resist (opening of a mask for plating) by electrolytic copper plating, and eight wiring patterns running parallel to each other along the longitudinal direction of the base insulating layer were formed, after which the mask for plating (resist) was peeled off and the exposed metal thin film was removed by etching.

The width of the copper wiring pattern was 30 μm, and a space between the adjacent patterns was 30 μm.

Then, in the same manner as in the base insulating layer, coating with a photosensitive polyimide precursor, exposure, development and heating were successively performed, a cover insulating layer (thickness: 5 μm) made from polyimide, which had a given pattern including an opening (part free of polyimide layer formation) on an end part that became a terminal part of the copper wiring pattern was formed, and a nickel (thickness: 5 μm)/gold (thickness: 0.2 μm) plating was applied to end part of the copper wiring pattern, which was exposed from the opening of the cover insulating layer, to form a terminal part.

Then, a photoresist pattern was formed on a surface opposite from the surface where the base insulating layer of the metal support plate (stainless substrate) was formed, and, using the photoresist pattern as a mask, both ends of the metal support plate (stainless substrate) in the width direction were removed by etching. By removing the photoresist pattern, the both ends of the base insulating layer in the width direction were protruded by 50 μm from the both ends (end part) of the metal support plate (stainless substrate) in the width direction. In this case, a metal support plate (stainless substrate) was removed from a half the area of the folding margin (to be connected to one of the two linear parts) and the boundary between said area and said one linear part, so that the base insulating layer can be exposed. As a result, the plan view from the metal support plate side was as shown in FIG. 10(b).

In this way, an FPC 200 of a size that fits in the square area (250 mm×250 mm) of FIG. 13 in a plan view was prepared.

The main substrate part 51A (to be inserted into a tube) is connected with a substrate part 51B (8 mm×8 mm) for connection with an external device.

The above-mentioned main substrate part 51A consists of three linear parts and two rectangle patterns connected to the three linear parts, and is a meander band. The rectangle pattern is a folding margin.

Each of the above-mentioned three linear parts has a length (D1) of 210 mm and a width (D2) of 1 mm, and the three parts are configured in parallel to each other with a 50 μm clearance (D4).

The above-mentioned rectangle pattern (folding margin) has a width (D3) of 2 mm in the direction perpendicular to its axis.

This FPC 200 was folded at the two folding margins to give a single linear product having a total length (=total length of the main substrate part 51A) of 622 mm and an epoxy adhesive was fed at a spot and cured between the facing substrates in the folding part. The thickness of the adhesive layer was set to 20 μm.

A fluorine resin tube having an inner diameter of 1.2 mm, an outer diameter of 1.5 mm, and a length (length in the axis direction) of 600 mm was prepared and through holes (size of hole: 2 mm×0.4 mm (quadrangle)) were formed on the side wall at 5 mm away from one end portion in the axis direction of the tube.

Then, a pressure sensor (whole size (length=3 mm, width=0.5 mm, thickness=250 μm), terminal size: 80 μm×80 μm (quadrangle)) was placed on an electronic component mounting part 52 partitioned in the end portion of the base insulating layer of FPC 200 converted to the aforementioned single linear product. The terminal of the pressure sensor and a terminal 20 formed in the end of the wiring pattern 11 were wire bonded with a gold wire to electrically connect them. Thereafter, the FPC 200 was inserted from the other end portion (posterior end side) of the aforementioned fluororesin tube in the axis direction. Then, via a through hole formed on the tube side wall, the gold wire connection between the terminal of the pressure sensor and the terminal formed in the end of the wiring pattern was sealed with an epoxy resin. A sealing silicone resin was further applied to the area surrounding the through hole of the tube and the clearance of the pressure sensor to give a catheter with a pressure sensor.

During the production of the catheter, FPC could be inserted smoothly into the tube. The obtained catheter with a pressure sensor contained eight wiring patterns but showed fine flexibility, and could be inserted into the body of test subjects (examinees) with good operability. The test subjects did not complain pain during insertion of the catheter.

This application is based on a patent application No. 2005-121493 filed in Japan, the contents of which are hereby incorporated by reference. 

1. A flexible printed circuit board for a catheter, which is formed in a single non-linear band-like pattern having a folding margin at a predetermined position, wherein said flexible printed circuit board can turn into a single linear product when folded at said folding margin.
 2. The flexible printed circuit board of claim 1, wherein-said single linear product has a total length of not less than 300 mm.
 3. The flexible printed circuit board of claim 1, which has a band-like meander pattern as a whole, which comprises multiple linear parts configured in about parallel to each other and a folding margin connected to one end in the longitudinal direction of two adjacent linear parts of said multiple linear parts, and which can turn into a single linear product when the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either of the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees.
 4. The flexible printed circuit board of claim 3, wherein the single linear product has a total length of not less than 300 mm.
 5. The flexible printed circuit board of claim 1, wherein the size of the band-like pattern as a whole before folding is within a 250 mm×250 mm square area.
 6. The flexible printed circuit board of claim 1, which further comprises a metal support plate disposed in an area other than the folding line.
 7. The flexible printed circuit board of claim 1, wherein two opposite substrate surfaces after folding at a folding margin are adhered via an adhesive layer.
 8. A catheter comprising the flexible printed circuit board of claim 1 in the form of a single linear product inserted in a tube.
 9. A production method of a catheter, which comprises step 1: folding the flexible printed circuit board of claim 1 at a folding margin to give a single linear product, and step 2: inserting the resulting flexible printed circuit board in a tube.
 10. The production method of claim 9, wherein the step (1) comprises adhering, via an adhesive layer, two opposite substrate surfaces after folding at a folding margin.
 11. A production method of a catheter, which comprises step 1: folding a flexible printed circuit board of the following (I) at a folding margin to give a single linear product, and step 2: inserting the resulting flexible printed circuit board in a tube, wherein, in step 1, the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either f the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees, so as to convert the circuit board into a single linear product; (I) a flexible printed circuit board for a catheter, which is formed in a single non-linear band-like pattern having a folding margin at a predetermined position, wherein said flexible printed circuit board can turn into a single linear product when folded at said folding margin, which has a band-like meander pattern as a whole, which comprises multiple linear parts configured in about parallel to each other and a folding margin connected to one end in the longitudinal direction of two adjacent linear parts of said multiple linear parts, and which can turn into a single linear product when the folding margin is double-folded such that a folding line parallel to the axis of the linear parts is formed in the about center thereof, and, at the folding margin, either of the two linear parts connected to said folding margin is folded back in the direction opposite by 180 degrees. 